Pocketed Spring Assembly Including Liquid Pods

ABSTRACT

A pocketed spring assembly comprises a plurality of parallel strings of springs, each string joined to at least one adjacent string, each string comprising one piece of fabric folded into first and second opposed plies. Outer pockets are formed along each string by transverse seams joining the first and second plies. One pocketed spring and at least one liquid pod are positioned in each outer pocket. At least one cushion pad, at least one liquid pod or any combination thereof may be individually pocketed inside an outer pocket.

FIELD OF THE INVENTION

This invention relates generally to bedding and seating products and,more particularly, to pocketed spring assemblies used in bedding andseating products.

BACKGROUND OF THE INVENTION

Mattress spring core construction over the years has been a continuouslyimproving art with advancements in materials and machine technology. Awell-known form of spring core construction is known as a Marshallspring construction wherein metal coil springs are encapsulated inindividual pockets of fabric and formed as elongate or continuousstrings of pocketed coil springs. In an earlier form, these strings ofcoil springs were manufactured by folding an elongate piece of fabric inhalf lengthwise to form two plies of fabric and stitching transverse andlongitudinal seams to join the plies of fabric to define pockets withinwhich the springs were enveloped.

Improvements in spring core constructions have involved the use offabrics which are thermally or ultrasonically weldable to themselves. Byusing such welding techniques, these fabrics have been advantageouslyused to create strings of individually pocketed coil springs whereintransverse and longitudinal welds, instead of stitching, are used toform the pockets encapsulating the springs.

Once strings of pocketed springs are constructed, they may be assembledto form a pocketed spring core or assembly for a mattress, cushion orthe like by a variety of methods. For example, multiple or continuousstrings may be arranged in a row pattern corresponding to the desiredsize and shape of a mattress or the like, and adjacent rows of stringsmay be interconnected by a variety of methods. The result is a unitaryassembly of pocketed coil springs serving as a complete spring coreassembly.

Conventional pocketed spring cores incorporating pocketed strings ofsprings have less motion transfer between sleeping partners whencompared to traditional helically-laced open coil spring assemblies.Each pocketed coil spring is able to move with greater independence and,therefore provide less influence on adjacent pocketed coil springs thanif the coil springs were not inside individual pockets. However, with atraditional pocketed spring mattress, a sheet of foam or othercushioning layer is attached to an upper surface of the pocketed springassembly. The foam or cushioning sheet or sheets acts like a bridge,such that a load applied to one side of a mattress may affect the otherside of the mattress, providing an undesirable bridging effect. Thepresent invention eliminates the undesirable bridging effect byencapsulating individual cushion members inside outer pockets of stringsof springs.

Another type of mattress once popular is known as a waterbed. A waterbedcomprises an outer vinyl cover or bladder filled with water. Onedisadvantage of waterbeds is the volume of water required to fill thebladder. Should the bladder break, the carpet and/or other parts of theroom in which the waterbed breaks may be damaged. To some users, awaterbed is desirable due to its unique feel and effect on sore muscles.

It would be desirable to incorporate the feel of a waterbed into aconventional mattress. Therefore, there is a need to combine multipletechnologies to improve the feel and motion transfer in a bedding orseating product having a pocketed spring core.

SUMMARY OF THE INVENTION

In one aspect, a bedding or seating product is provided. The productcomprises a pocketed spring assembly comprising a plurality of parallelstrings of springs, each string joined to at least one adjacent string.Each string comprises a piece of fabric surrounding a plurality of innerpocketed springs and a plurality of liquid pods, first and secondopposed plies of fabric being on opposite sides of the inner pocketedsprings and liquid pods. Outer pockets are formed along the length ofthe string by a longitudinal seam and transverse seams joining the firstand second plies. At least one inner pocketed spring and at least oneliquid pod are in each of the outer pockets.

Each liquid pod may comprise an outer, protective pouch, a filler and aplurality of beads inside the outer, protective pouch. The pouch may bemade of any flexible but strong, non-permeable hydrophobic membrane. Thepouch may be made from a variety of polymeric materials including, butnot limited to, natural or synthetic rubber or deblock or triblockcopolymer resins, potentially melted or mixed with a plasticizing agent,such as mineral oil, synthetic oil, etc. Triblock copolymers include,but are not necessarily limited to, (SB)n styrene-butadiene, (SEB)n,(SIS) styrene-isoprene-styrene block copolymers, (SEBS)styrene-ethylene-butylene-styrene block copolymers, (SEP)styrene-ethylene-propylene block copolymers, (SEEPS)styrene-ethylene-ethylene-propylene-styrene block copolymers, (SBS)styrene-butadiene-styrene block copolymers and the like. Alternatively,the pouch may be made of polyurethane elastomer or silicone. The pouchesmay contain additives such as colors or antimicrobial additives. Thepouches of the liquid pods may be made at least partially of renewableor recycled material.

The filler may be a solid, a liquid or a hydrogel at room temperature.In the event the beads are filled with liquid, the liquid may be water,glycerol or other gylcols or synthetic or natural oils. The liquid maycontain additives such as colors or antimicrobial additives. The liquidmay contain at least some water. The water may be mixed with a modifiersuch as a known component to lower the freezing point of water.

Alternatively, the filler may be a solid such as a wax or phase changematerial (“PCM”) which is solid at room temperature but which turns toliquid when heated, such as when a person lays on a product containingsuch phase change materials. The phase change material absorbs the heatfrom the person, thereby changing the solid to a liquid. Phase changematerials are considered latent heat storage units and can be defined asa substance with a high heat of fusion which can store and release largeamounts of energy as it undergoes a phase transition, namely between thesolid and liquid phases.

PCMs can be divided into the following, non-limiting classifications:Organic PCMs, which including but not limited to paraffins of the formC_(n)H_(2n+2), and fatty acids of the form CH₃(CH₂)_(2n)COOH; inorganicPCMs, including, but not limited to, salt hydrates of the form M_(n)H₂O;eutectics, comprising organic-organic, organic-inorganic, andinorganic-inorganic compounds; and hygroscopic materials.

Examples of organic PCMs include, but are not limited to, water,NaCl.Na₂SO₄.10H₂O, sodium sulfate (Na₂SO₄.10H₂O), Na₂SiO₃.5H₂O, lithium,NaNO₂ NaCl (5.0%)/NaNO₃, NaOH/Na₂CO₃ (7.2%), NaCl/NaNO₃ (5.0%), NaCl(5.7%)/NaNO₃ (85.5%)/Na₂SO₄, KNO₃ (10%)/NaNO₃, NaNO₃, NaOH, KNO₃/KCl(4.5%), lead, KNOB, KNO₃/KBr (4.7%)/KCl (7.3%), NaCl/KCL (32.4%)/LiCl(32.8%), KOH, NaCl (26.8%)/NaOH, zinc, aluminium, silver, gold, copper,iron, titanium, Mn(NO₃)₂.6H₂O+MnCl₂.4H₂O_((4 % w/w)), and NaCl(42.5%)/KCl (20.5)/MgCl₂.

Examples of non-organic PCMs include, but are not limited to, paraffin14-carbons, formic acid, paraffin 15-carbons, caprilic acid, paraffin16-carbons, acetic acid, glycerin, polyethylene glycol 600, paraffin17-carbons, p-lattic acid, paraffin 18-carbons, methyl palmitate,Trimethylolethane (TME)_((63% w/w))+H₂O_((37% w/w)), paraffin19-carbons, trimyristin, capric acid, paraffin 20-carbons, camphenilone,docasyl bromide, caprylone, paraffin 21-carbons, phenol, heptadecanone,1-cyclohexylooctadecane, 4-heptadacanone, p-toluidine, paraffin22-carbons, cyanamide, lauric acid, methyl eicosanoate, elaidic acid,paraffin 23-carbons, 3-heptadecanone, 2-heptadecanone, hydrocinnamicacid, cetyl acid, paraffin 25-carbons, camphene, o-nitroaniline,paraffin 24-carbons, 9-heptadecanone, thymol, methyl behenate,pentadecanoic acid, diphenyl amine, p-dichlorobenzene, oxolate,hypophosphoric acid, o-xylene dichloride, palmitic acid, p-chloroaceticacid, chloroacetic acid, tristearin, paraffin 26-carbons, nitronaphthalene, myristic acid, paraffin 27-carbons, α-naphthylamine,heptadecanoic acid, α-chloroacetic acid, paraffin 28-carbons, bee wax,bees wax, glycolic acid, glycolic acid, paraffin 29-carbons,p-bromophenol, paraffin 30-carbons, azobenzene, paraffin 31-carbons,acrylic acid, stearic acid, paraffin 32-carbons, dinitrotoluene (2,4),paraffin 33-carbons, paraffin 34-carbons, phenylacetic acid,thiosinamine, bromocamphor, benzylamine, durene, methyl bromobenzoate,acetamide, alpha naphthol, glutaric acid, p-xylene dichloride, methylfumarate, catechol, quinone, acetanilide, succinic anhydride, benzoicacid, stilbene, and benzamide.

The beads may be hydrogel products which constitute a group of naturalor synthetic polymeric materials. The hydrophilic structure of thepolymeric materials enables them to hold large amounts of water in theirthree-dimensional network. Natural polymers for hydrogel preparationinclude hyaluronic acid, chitosan, heparin, alginate and fibrin. Commonsynthetic polymers include polyvinyl alcohol, polyethylene glycol,sodium polyacrylate, acrylate polymers and copolymers thereof.

An alternative liquid pod may lack the beads but instead may comprise anouter pouch containing a volume of liquid such as water or glycerin or aquantity of solid such as a phase change material. The pouch of such aliquid pod may be made of the same flexible but strong, non-permeablehydrophobic membrane such as the membrane described above with respectto the pouch containing beads.

At least one cushion pad may also be incorporated into each outer pocketof the pocketed spring assembly. Each cushion pad is preferably at leastpartially made of foam but may be made of fiber or some combination offoam and fiber. In a one-sided pocketed spring assembly, a cushion padmay be located between the liquid pod and the inner pocketed springinside the outer pocket. Alternatively, the liquid pod may be locatedbetween the cushion pad and the inner pocketed spring inside the outerpocket.

In a two-sided pocketed spring assembly, a cushion pad and a liquid podmay be on each side of the inner pocketed spring such that two cushionpads, two liquid pods and one inner pocketed spring are encased by theouter pocket. In some embodiments, at least one cushion pad and at leastone liquid pod may be pocketed together and may be any desired size orshape.

Different coil springs may be located inside the inner pockets. In oneembodiment, each of the coil springs has upper and lower end turns and aplurality of central convolutions between the end turns, theconvolutions decreasing in diameter and pitch from a middle portion ofthe spring towards at least one of the end turns. In another embodiment,each of the coil springs has upper and lower end turns and a pluralityof central convolutions between the end turns, each of the convolutionsbeing the same diameter. Regardless of the configuration of coil spring,each coil spring is preferably made of one piece of wire of a uniformdiameter, but not in all cases.

In some embodiments, an upper end of each transverse seam formingadjacent pockets of the string is below an upper surface of the stringof springs to partially separate adjacent outer pockets. In otherembodiments, such as double-sided pocketed spring assemblies, each endof each transverse seams has a length less than the height of the of thestring to partially separate adjacent outer pockets. In the beddingindustry, pocketed spring assemblies having such transverse seams aresaid to have a “split top” feature. Cushioning materials may be placedon the pocketed spring assembly, and a covering, usually an upholsteredcovering, encases the pocketed spring assembly and cushioning materials.

The strings may extend longitudinally (from end-to-end) or transversely(from side-to-side). A pocketed spring assembly for use in a bedding orseating product may be posturized into regions or zones of differentfirmness by incorporating different strings into the pocketed springassembly.

If the strings extend transversely, the pocketed spring assembly mayinclude a plurality of the strings having outer pockets containing atleast one liquid pod and other strings lacking liquid pods, the stringsarranged in a plurality of zones longitudinally spaced apart. Forexample, the pocketed spring assembly may include three such zones. Thethree zones may comprise a central zone, a head end zone and a foot endzone. The end zones may comprise strings lacking liquid pods, and thestrings comprising the central zone may comprise strings having liquidpods. Alternatively, the end zones may have certain types of liquidpods, and the strings comprising central zone may comprise stringshaving different liquid pods.

If the strings extend longitudinally, the pocketed spring assembly mayinclude strings having at least one liquid pod in each outer pocket andother strings lacking liquid pods, the strings arranged in a pluralityof zones transversely spaced apart. For example, the pocketed springassembly may include two such zones, a “warm” zone and a “cool” zone.The “cool” side or zone may comprise strings of springs having at leastone liquid pod in each outer pocket, and the “warm” side or zone cancomprise strings of springs lacking liquid pods. Alternatively, thedifferent zones may have different types of liquid pods incorporatedtherein.

In another aspect, a pocketed spring assembly for a bedding or seatingproduct is provided. The pocketed spring assembly comprises a pluralityof parallel strings. Each string is joined to at least one adjacentstring. Each of the strings comprises a plurality of interconnectedouter pockets made from one piece of fabric. Each of the outer pocketscontains at least one inner pocketed spring, at least one cushion padand at least one liquid pod. The piece of fabric is joined to itselfalong a longitudinal seam and has first and second opposed plies offabric on opposite sides of the inner pocketed springs. The first andsecond plies of fabric are joined by transverse seams between adjacentinner pocketed springs.

In some embodiments, each of the transverse seams forming the adjacentouter pockets of the string has one end located below an upper surfaceof the string to partially separate adjacent outer pockets. Inembodiments of double sided pocketed spring assemblies, each of thetransverse seams forming the adjacent outer pockets of the string hasone end located below an upper surface of the string and the other endlocated above a lower surface of the string. Such a string is consideredto have the “split top” feature on both sides of the string.

In another aspect, a string of springs for a pocketed spring assemblyfor a bedding or seating product is provided. The pocketed springassembly comprises a plurality of parallel strings of springs. Eachstring is joined to an adjacent string. Each of the strings comprises aplurality of interconnected outer pockets made from one piece of fabric.Each of the outer pockets contains at least one inner pocketed springand at least one liquid pod. The piece of fabric is joined to itselfalong a longitudinal seam and has first and second opposed plies offabric on opposite sides of the inner pocketed springs. The fabric ofthe first and second plies is joined by transverse seams which areshorter than the string. Each of the transverse seams forming theadjacent outer pockets of the string has an upper end located below anupper surface of the string to partially separate adjacent outer pocketsand enable some of the liquid pods to flex or move without substantiallyflexing the liquid pods within other outer pockets of the string.

One advantage of the present invention is that when a bedding or seatingproduct, such as a mattress, is manufactured, the manufacturer need notplace one or more sheets of cushioning material over the pocketed springassembly prior to the unit being upholstered. The mattress manufacturermay simply place a cover around the pocketed spring assembly withoutusing any sheets of cushioning material.

Another advantage of the present invention is that the inner pocketedcoil spring does not press into the liquid pod or cushion padabove/below it when subjected to a load. Because the inner pocketedspring is retained in its own inner pocket independent of the cushionpad or pads or liquid pod or pods, the inner pocketed spring does notexert force on the cushion pad or pads or liquid pod or pods, therebypreserving the designed characteristics of the cushion pad or pads orliquid pod or pods such as firmness, for example. The inner pockets offabric surrounding the coil springs and/or the fabric surrounding eachcushion pad or liquid pod preserves the integrity of the cushion pads orliquid pods and increases the life of the pocketed spring assembly. Theresult is that the user “feels” more of the cushion pad or pads orliquid pod or pods.

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate embodiments of the invention and,together with the summary of the invention given above, and the detaileddescription of the drawings given below, explain the principles of thepresent invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view, partially broken away, of a bedding orseating product incorporating a pocketed spring assembly according tothe principles of the present invention.

FIG. 1A is a perspective view, partially broken away, of a bedding orseating product incorporating another pocketed spring assembly.

FIG. 1B is a perspective view, partially broken away, of a double-sidedbedding product incorporating another pocketed spring assembly.

FIG. 1C is a perspective view, partially broken away, of another beddingproduct incorporating the pocketed spring assembly of FIG. 1 .

FIG. 2 is a perspective view, partially broken away, of a portion of astring of springs of the pocketed spring assembly of FIG. 1 in anunloaded condition.

FIG. 2A is a perspective view, partially broken away, of a portion ofanother string of springs in an unloaded condition.

FIG. 2B is a perspective view of a liquid pod in a relaxed condition.

FIG. 2C is a perspective view of a different liquid pod in a relaxedcondition.

FIG. 3 is a cross-sectional view, partially broken away, of the portionof the string of FIG. 2 in an unloaded condition.

FIG. 3A is a cross-sectional view, partially broken away, of a portionof an alternative string in an unloaded condition.

FIG. 3B is a cross-sectional view, partially broken away, of the portionof the string of FIG. 3A showing two pocketed springs being in a loadedcondition.

FIG. 3C is a cross-sectional view, partially broken away, of a string ofsprings having a different spring in an unloaded condition.

FIG. 3D is a cross-sectional view, partially broken away, of a string ofsprings having a different spring in an unloaded condition.

FIG. 4 is a perspective view of a portion of the pocketed springassembly of FIG. 1 in a relaxed condition.

FIG. 5 is a perspective view of a portion of another pocketed springassembly in a relaxed condition, the strings of springs being offsetfrom one another.

FIG. 6 is a cross-sectional view, partially broken away, of anotherstring of springs in an unloaded condition.

FIG. 6A is a cross-sectional view, partially broken away, of anotherstring of springs in an unloaded condition.

FIG. 7 is a cross-sectional view, partially broken away, of double-sidedstring of springs in an unloaded condition.

FIG. 8 is a cross-sectional view, partially broken away, of double-sidedstring in an unloaded condition.

FIG. 9 is a cross-sectional view, partially broken away, of double-sidedstring in an unloaded condition.

FIG. 10 is a cross-sectional view, partially broken away, of anotherdouble-sided string in an unloaded condition.

FIG. 11 is a cross-sectional view, partially broken away, of a portionof the string of FIG. 10 in an unloaded condition.

FIG. 12 is a cross-sectional view, partially broken away, of anotherdouble-sided string in an unloaded condition.

FIG. 13 is a schematic cross-sectional view of a single-sided string inan unloaded condition.

FIG. 14 is a schematic cross-sectional view of another single-sidedstring in an unloaded condition.

FIG. 14A is a schematic cross-sectional view of another single-sidedstring in an unloaded condition.

FIG. 15 is a schematic cross-sectional view of another single-sidedstring in an unloaded condition.

FIG. 15A is a schematic cross-sectional view of another single-sidedstring in an unloaded condition.

FIG. 16 is a schematic cross-sectional view of a double-sided string inan unloaded condition.

FIG. 17 is a schematic cross-sectional view of another double-sidedstring in an unloaded condition.

FIG. 17A is a schematic cross-sectional view of another double-sidedstring in an unloaded condition.

FIG. 18 is a schematic cross-sectional view of another double-sidedstring in an unloaded condition.

FIG. 18A is a schematic cross-sectional view of another double-sidedstring in an unloaded condition.

FIG. 19 is a top view of a posturized pocketed spring assemblyconstructed in accordance with the present invention.

FIG. 20 is a top view of another posturized pocketed spring assemblyconstructed in accordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Referring first to FIG. 1 , there is illustrated a bedding product inthe form of a single-sided mattress 10 incorporating the principles ofthe present invention. This product or mattress 10 comprises a pocketedspring assembly 12 over the top of which there lay conventional paddingor cushioning layers 14, 16 which may be foam, fiber, gel, a pocketedspring blanket or any other suitable materials or any combinationthereof. The pocketed spring assembly 12 includes a central portion 15and border 17 surrounding the central portion 15. The pocketed coilsprings 11 of the border 17 may be of a different diameter than pocketedcoil springs 28 of the central portion 15. Although one type of border17 is illustrated, the border may assume other forms or shapes of anydesired size, such as pocketed coil springs of different geometries thanthe pocketed springs of the central portion. Alternatively, the border17 may be omitted in any embodiment described or shown herein. Thepocketed spring assembly 12 is mounted upon a base 18 and is completelyenclosed within an upholstered covering material 20.

As shown in FIG. 1 , fully assembled, the product 10 has a length “L”defined as the linear distance between opposed end surfaces 22 (only onebeing shown in FIG. 1 ). Similarly, the assembled product 10 has a width“W” defined as the linear distance between opposed side surfaces 24(only one being shown in FIG. 1 ). In the product shown in FIG. 1 , thelength is illustrated as being greater than the width. However, it iswithin the scope of the present invention that the length and width maybe identical, as in a square product.

As shown in FIG. 1 , the central portion 15 of pocketed spring assembly12 is manufactured from multiple strings 26 of pocketed springs 28joined together. Each string of pocketed springs 26 extendslongitudinally or from head-to-foot along the full length of the product10.

Although in the central portion 15 of the pocketed spring assembly 12the strings of pocketed springs 26 are illustrated as extendinglongitudinally or from head-to-foot, they may extend transversely orfrom side-to-side as shown in the pocketed spring assembly 12 a ofproduct 10 a shown in FIG. 1A. The central portion 15 of pocketed springassembly 12 a comprises multiple strings 26 a of pocketed springs,identical to the strings of springs 26, but shorter in length.

FIG. 1B illustrates a double-sided mattress 10 b comprising a pocketedspring assembly 12 b having a central portion 15 and border 17, as shownin the mattress 10 of FIG. 1 . However, the mattress 10 b of FIG. 1B hasconventional padding layers 14, 16 above and below a double-sidedpocketed spring assembly 12 b. The central portion 15 of thedouble-sided pocketed spring assembly 12 b comprises a plurality ofstrings 26 b of pocketed springs, one being partially shown incross-section in FIG. 7 .

FIG. 1C illustrates a single-sided mattress 10 c comprising a pocketedspring assembly 12 having a central portion 15 and border 17, as shownin the mattress 10 of FIG. 1 . However, the mattress 10 c of FIG. 1C hasa pocketed topper 19 comprising miniature pocketed coil springs inaddition to padding layers 14, 16 above the pocketed topper 19. A scrimlayer 21 separates the pocketed topper 19 from the pocketed springassembly 12. Although one configuration of pocketed topper 19 isillustrated, any pocketed topper or comfort layer known in the art maybe used.

According to this invention, any of the padding or cushioning layers,including the pocketed topper 19, may be omitted in any of theembodiments shown or described herein. The novel features reside in thepocketed spring assembly, in at least one of the central portion orborder of the pocketed spring assembly.

These strings of pocketed springs 26, 26 a and 26 b, and any otherstrings of springs described or shown herein, may be connected inside-by-side relationship as, for example, by gluing the sides of thestrings together in an assembly machine, to create an assembly or matrixof springs having multiple rows and columns of pocketed springs boundtogether as by gluing, welding or any other conventional assemblyprocess commonly used to create pocketed spring cores or assemblies.

Referring to FIGS. 4 and 5 , the strings 26 of pocketed springs may bejoined so that the individually pocketed springs 28 are aligned intransversely extending rows 30 and longitudinally extending columns 32.Alternatively, the strings 26 of pocketed springs may be offset from oneanother in a pocketed spring assembly. In such an arrangement, shown inFIG. 5 , the individually pocketed springs 28 are not aligned in rowsand columns; instead the individually pocketed springs 28 fill gaps orvoids 70 of the adjacent strings 26. FIG. 5 shows a portion of apocketed spring assembly 12′ with multiple strings 26 arranged in thismanner. Either alignment of strings may be incorporated into any of thepocketed spring assemblies or cores illustrated or described herein.Although FIGS. 4 and 5 illustrate strings 26, the same alignments may beused in any pocketed spring assembly disclosed herein having any stringsdisclosed herein including strings 26 a or 26 b.

As best illustrated in FIGS. 2 and 3 , each string 26 of pocketedsprings 28 comprises a row of interconnected fabric outer pockets 34.Each of the fabric outer pockets 34 contains at least one inner pocketedcoil spring 82, at least one cushion pad 54 and at least one liquid pod55. Each inner pocketed coil spring 82 comprises a coil spring 36encased in an inner pocket 35 having two side seams 37. The inner pocket35 may be made of a single piece of fabric or any number of pieces offabric.

FIGS. 2 and 3 illustrate a one-sided string 26 for use in a single-sidedpocketed spring assembly, such as pocketed spring assembly 12. In string26, one cushion pad 54 rests on the fabric of the inner pocket 35 abovethe individually pocketed coil spring 36. In this orientation, the coilspring 36 is prevented from contacting and damaging the material of thecushion pad 54.

In string 26, one liquid pod 55 rests on the cushion pad 54 above thecushion pad 54. In the drawings the liquid pod 55 is illustrated havingapproximately the same height as the cushion pad 54. However, the liquidpod 55 may have a different height than the cushion pad 54.

For ease of understanding, FIG. 2 illustrates the leftmost outer pocket34 shown in dashed lines and the inner pocket 35 shown in solid lines.In FIG. 2 , the other outer pockets 34 of string 26 are shown in solidlines and the inner pockets 35 shown in dashed lines.

As best shown in FIG. 2 , the cushion pad 54 is shown as being shapedlike a hockey puck or puck-shaped. Cushion pad 54 is illustrated havinga circular upper surface 76, a circular lower surface 78 and a sidewall80.

As best shown in FIGS. 2 and 2B, the liquid pod 55 is shown ascomprising an outer pouch 57 surrounding a plurality of beads 59 andfiller 63. The filler 63 may comprise a volume of liquid such as wateror glycerin or a volume of hydrogel or a quantity of solid material suchas a phase change material described above. Although the beads 59 areillustrated all being the same size, they may be different sizes withinthe liquid pod 55. The outer pouch 57 does not to be filled with beads59; any desired quantity of beads 59 may be located inside the outerpouch 57 of the liquid pod 55. The drawings are not intended to belimiting. Similarly, the amount of filler 63 may be any desired volumeor mass; the drawings are not intended to be limiting.

The outer pouch 57 may be made of any flexible but strong, non-permeablehydrophobic membrane. The outer pouch 57 may be made from a variety ofpolymeric materials including, but not limited to, natural or syntheticrubber or deblock or triblock copolymer resins, potentially melted ormixed with a plasticizing agent, such as mineral oil, synthetic oil,etc. rubber or any type of plastic such as vinyl, polyurethane, polyureaor silicone. The membrane of the outer pouch 57 may include any knownplastic or natural or synthetic rubber including but not limited tosilicone, polyurethane and polyurea.

As shown in FIGS. 2C, another embodiment of liquid pod 55′ may beincorporated into any comfort layer shown or described herein. Liquidpod 55′ comprises an outer pouch 57′ surrounding a filler 63′. Theliquid pod 55′ contains no beads. The outer pouch 57′ may be made ofrubber or any type of plastic such as vinyl, polyurethane, polyurea orsilicone. The filler 63′ contained inside the outer pouch 57′ may bewater or glycerin. The filler 63′ contained inside the outer pouch 57′may be a volume of liquid such as water or glycerin or a volume ofhydrogel or a quantity of solid material such as a phase change materialas described above.

In any of the embodiments shown or described herein, the liquid pods 28,28′ may be any desired size. Although the beads 59 are illustrated allbeing the same size, they may be different sizes within a liquid pod 28.The drawings are not intended to be limiting.

FIG. 2A illustrates a string 27 identical to string 26 but having adifferent cushion pad 54 a. Cushion pad 54 a has a different shape thancushion pads 54 inside the inner pockets 35 of the string 27. FIG. 2Aillustrates a cushion pad 54 a having a rectangular upper surface 76 a,a rectangular lower surface 78 a and four rectangular sidewalls 80 a.Although FIG. 2A illustrates square upper and lower surfaces andsidewalls, one or more surfaces or sidewalls may be other rectangularshapes. Although FIGS. 2 and 2A illustrate cushion pads 54, 54 a,respectively, and liquid pods 55 of a certain size and shape, thedrawings are not intended to limit the size or shape of the cushion padsor liquid pods.

Each cushion pad 54, 54 a is illustrated being a single piece ofmaterial, such as foam, but may be any number of pieces of any desiredmaterial joined together. Alternatively, the cushion pad 54, 54 a may bemade of fiber, cotton, gel or any combination thereof.

The coil spring 36 is preferably made of one piece of wire of a uniformdiameter, but may be made of other materials, multiple strands oftwisted wire and/or may be a non-uniform diameter. As best shown in FIG.2 , each coil spring 36 has a central or longitudinal axis A, an upperend turn 38, a lower end turn 40 and a plurality of central convolutions42 between the end turns. FIGS. 2 and 3A illustrate a barrel-shaped coilspring 36 in which the diameter of the end turns 38, 40 is less than thediameter of the central convolutions 42, the central convolutions 42tapering or decreasing in diameter and pitch as one moves from a centeror middle portion 44 of the coil spring towards the end turns. As bestshown in FIG. 2 , each barrel-shaped coil spring 36 has two end portionswhich are not identical, an upper end portion 46 and a lower end portion48.

Preferably, one piece of fabric is used to create the outer pockets 34of the string 26 of pocketed springs 36, the piece of fabric beingfolded over onto itself around the inner pocketed coil springs 82, thecushion pads 54 and the liquid pods 55. As best shown in FIG. 2 ,opposite sides or plies 47, 49 of the fabric are sewn, welded orotherwise secured together to create a longitudinal seam 50 and aplurality of separating or transverse seams 52. FIG. 2 illustrates ply47 being closest to the reader and ply 49 being behind the coil springs36.

Although the seams or welds in the embodiments shown herein are shown asbeing welded spaced rectangles, any of the seams may be spaced dots,triangles or solid line segments without spaces.

As best shown in FIG. 2 , opposed edges 56 of the piece of fabric usedto create the string 26 of pocketed springs are aligned and spaced fromthe longitudinal seam 50 a distance indicated by numeral 58. Althoughthe drawings indicated the longitudinal seam 50 being below the freeedges 56 of the piece of fabric, the longitudinal seam 50 may be abovethe free edges 56 of the piece of fabric.

As shown in FIGS. 2 and 3 , the piece of fabric used to create thestring 26 has a plurality of upper ears 53 and lower ears 83. When theears are collapsed, the string 26 has a generally planar top surface 60in a top plane P1 and a parallel generally planar bottom surface 62 in abottom plane P2. The linear distance between the top and bottom surfaces60, 62 of the string 26 defines a height “H” of the string 26. Thislinear distance further defines the height H of the pocketed springassembly 12 because each of the strings 26 has the same height. However,it is within the scope of the present invention that different stringsof springs of a pocketed spring assembly have different heights.

As shown in FIGS. 2 and 3 , in one embodiment, the transverse seams 52of string 26 separating adjacent pockets extend from the top of an upperear 53 of fabric to the bottom of a lower ear 83 of fabric. In analternative embodiment shown in FIGS. 3A and 3B, the transverse seams152 of string 126 separating adjacent pockets extend short of the upperand lower ears 53, 83 of fabric, respectively. In the alternativeembodiment shown in FIGS. 3A and 3B, each transverse seam 152 is shorterthan the height of the string 126 due to divides 64 described herein.

In accordance with the alternative embodiment shown in FIGS. 3A and 3B,in strings 126, the transverse seams 152 separating adjacent outerpockets 34 are divided with divides 64 which may be in the form cuts,slits, or notches created by, for example, cutting, slitting, severing,melting, or the like, from the upper surface 60 of the string 126inwardly (downwardly as illustrated), to partially separate the adjacentouter pockets 34. Preferably, the divide 64 extends to beyond or belowthe liquid pod 55 but may be any desired length including less than theheight of the liquid pod 55. As best shown in FIGS. 3A and 3B, thetransverse seams 152 of the strings 126 each have an upper end 66located at the bottom of each divide 64 and a lower end (not shown). Asshown in FIG. 3A, the upper end 66 of each transverse seam 152 islocated below adjacent liquid pod 55 when the inner pocketed coilsprings 36 are in a relaxed condition and not loaded. Like the string 26b shown in FIG. 7 , in a double-sided pocketed spring assembly, thelower end of each transverse seam 152 of the strings 26 b may have adivide 64 extending upwardly from a lower surface 62 of the string 26 b.

The significance of divide 64 may be appreciated with reference to FIG.3B. Divide 64 essentially decouples each liquid pod 55 from its adjacentliquid pod 55 during initial deflection of liquid pod 55. This createsmore of an individual coil performance and allows the inner pocketedcoil spring 82 to engage a person sleeping on the mattress 10 soonerwhile giving the person a softer feel at the beginning of the coildeflections. It is believed that this arrangement provides a morecomfortable pocketed spring assembly 12.

FIG. 6 illustrates another embodiment of string 26 c which may be usedin any of the pocketed spring assemblies or products shown or describedherein. The string 26 c comprises the same seams, same inner pocketedsprings 82 and outer fabric pockets 34 as incorporated into strings 26.However, each of the outer fabric pockets 34 includes a combination pad51 above the inner pocketed coil spring 82. The combination pad 51comprises a cushion pad 54 and a liquid pod 55 which in combination areencased in a fabric cover 84. Each combination pad 51 has its own fabriccover 84 which prevents the coil spring 36 of the inner pocketed coilspring 82 from contacting and damaging the cushion pad or pads overtime, in addition to the inner pocket 35 of fabric of the inner pocketedcoil spring 82. Although FIG. 6 illustrates each combination pad 51comprising one cushion pad 54 and one liquid pod 55 encased in a fabriccover 84, a combination pad may include more than one cushion pad and/ormore than one liquid pod. It is also within the scope of the inventionthat the combination pad 51 comprises one liquid pod 55 and one cushionpad 54 encased in a fabric cover 84, the liquid pod 55 being closer tothe inner pocketed coil spring 82.

FIG. 6A illustrates another embodiment of string 26 cc which may be usedin any of the pocketed spring assemblies or products shown or describedherein. The string 26 cc comprises the same seams, same inner pocketedsprings 82 and outer fabric pockets 34 as incorporated into strings 26.However, each cushion pad 54 is encased in a fabric cover 84 b and eachliquid pod 55 is encased in a fabric cover 84 a. Thus, each cushion pad54 has its own fabric cover 84 b which prevents the coil spring 36 ofthe inner pocketed coil spring 82 from contacting and damaging thecushion pad or pads over time, in addition to the inner pocket 35 offabric of the inner pocketed coil spring 82.

FIG. 7 illustrates another embodiment of string 26 b which may be usedin any of the double-sided pocketed spring assemblies such asdouble-sided pocketed spring assembly 12 b used in double-sided mattress10 b shown in FIG. 1B. Although string 26 b shown in FIG. 7 is shownhaving the split top feature like the strings 126 shown in FIG. 3A, anystrings shown or disclosed herein may lack the split top featureregarding of whether single-sided or double-sided. Any of the stringsshown herein may be incorporated into any bedding or seating product,including any double-sided mattress or seating cushion. For example,while the mattresses 10, 10 a and 10 c illustrated in FIGS. 1, 1A and1C, respectively, are single-sided mattresses having single-sidedpocketed spring assemblies 12, 12 a and 12 c, respectively,incorporating single-sided strings, any of the strings shown ordescribed herein as being single-sided, may be double-sided for use in adouble-sided mattress or seating cushion. Likewise, any of the stringsshown or described herein as being double-sided, may be single-sided foruse in a single-sided mattress or seating cushion.

FIG. 7 illustrates a portion of a string of springs 26 b used in adouble-sided pocketed spring assembly, like pocketed spring assembly 12b shown in FIG. 1B. The fabric outer pockets 34 b of such strings 26 bare slightly different than the fabric outer pockets 34 of string ofsprings 26. There are divides 64 along the tops and bottoms of thestrings 26 b.

FIG. 7 illustrates a two-sided string 26 b for use in a double-sidedpocketed spring assembly 12 b, as shown in FIG. 1B. Two cushion pads 54are located inside each outer pocket 34 b along with an inner pocketedspring 82 b located between the cushion pads 54. One of the cushion pads54 is located above the inner pocketed coil spring 82 b and the othercushion pad 54 is located below the inner pocketed coil spring 82 b.Although FIG. 7 illustrates cushion pads 54 lacking covers, encasedcushion pads 51 or cushion pads of different shapes, such as shown inFIG. 2A, may be used in the double-sided string 26 b or any string shownor described herein.

Two liquid pods 55 are located inside each outer pocket 34 b along withtwo cushion pads 54 and an inner pocketed spring 82 b located betweenthe cushion pads 54 and between the liquid pods 55. One of the liquidpods 55 is located above one of the cushion pads 54 and above the innerpocketed coil spring 82 b. The other liquid pod 55 is located below theother cushion pad 54 and the inner pocketed coil spring 82 b. AlthoughFIG. 7 illustrates liquid pods 55 lacking covers, encased liquid pods orliquid pods of different shapes, or any combination thereof, may be usedin the double-sided string 26 b or any string shown or described herein.

As shown in FIG. 7 , the coil springs 36 b of inner pocketed springs 82b are different than the coil springs 36 of inner pocketed springs 82shown in FIGS. 2 and 3 . Each coil spring 36 b comprises a central orlongitudinal axis A1, an upper end turn 38 b, a lower end turn 40 b anda plurality of central convolutions 42 b between the end turns. FIGS. 1Band 7 illustrate a barrel-shaped coil spring 36 b in which the diameterof the end turns 38 b, 40 b is less than the diameter of the centralconvolutions 42 b, the central convolutions 42 b tapering or decreasingin diameter and pitch as one moves from a center or middle portion 44 bof the coil spring towards the end turns. As best shown in FIG. 7 , eachbarrel-shaped coil spring 36 b has two identical end portions 46 b.

FIGS. 3C and 3D illustrate portions of other embodiments of strings 26d, 26 e, respectively, which may be incorporated into any of theproducts shown or described herein. The strings 26 d, 26 e each comprisethe same seams and outer pockets 34 as incorporated into strings 26shown in FIGS. 2 and 3 . However, the springs 36 d, 36 e within thestrings 26 d, 26 e, respectively are different than the springs 36 ofstrings 26. Although springs 36 d, 36 e are only shown in FIGS. 3C and3D, they may be used in any string shown or described herein, includingtwo-sided strings having cushion pads and liquid pods above and beloweach inner pocketed coil spring regardless of the coil spring.

As shown in FIG. 3C, coil springs 36 d (only one being shown) each haveidentical end turns 38 d of a smaller diameter than the centralconvolutions 42 d therebetween in a central portion 44 d thereof. Thecentral convolutions 42 d of coil springs 36 d are identical having thesame diameter which is greater than the diameter of end turns 38 d.

As shown in FIG. 3D, coil springs 36 e (only one being shown) each havetwo identical end portions 46 e and a central portion 44 e therebetween.The central portion 44 e has more convolutions than each end portion 46e, as shown in FIG. 3D. Each coil spring 36 e has identical end turns 38e of a larger diameter than the central convolutions 42 e therebetweenof the central portion 44 e. The central convolutions 42 e of coilsprings 36 e have a smaller diameter than the diameter of end turns 38e.

FIG. 8 illustrates another embodiment of string 26 d which may be usedin any of the double-sided pocketed spring assemblies or products shownor described herein. The double-sided string 26 d comprises the sameseams, same coil springs 36 b and outer fabric pockets 34 b asincorporated into strings 26 b shown in FIG. 7 . However, each coilspring 36 lacks an inner pocket but has two individually pocketedcombination pads 51.

Like the combination pads 51 shown in FIG. 6 , each of the outer fabricpockets 34 b includes a combination pad 51 above the coil spring 36 b.However, in double-sided string 26 d, a second combination pad 51 islocated below the coil spring 36 b. Each combination pad 51 comprises acushion pad 54 and a buckling member 55 which in combination are encasedin a fabric cover 84. Each combination pad 51 has its own fabric cover84 which prevents un-pocketed coil spring 36 b from contacting anddamaging the cushion pad or pads over time.

Although string 26 d is shown as a double-sided string, the conceptillustrated therein of combining an un-pocketed coil spring withpocketed combination pads may be incorporated into any of the strings orpocketed spring assemblies shown or described herein, including singlesided strings and single-sided pocketed spring assemblies. Any of thecoil springs shown or described herein may be used in a version in whichthe cushion pad or pads/buckling member or buckling members is pocketedand the coil spring has no inner pocket, just an outer pocket.

FIG. 9 illustrates another embodiment of string 26 e which may be usedin any of the pocketed spring assemblies or products shown or describedherein. The double-sided string 26 e comprises transverse seams 252,same inner pocketed springs 82 b including same coil springs 36 b asshown in FIG. 7 , cushion pads 54 and cushion members 55. Each cushionpad 54 is encased in a fabric cover 84 b and each buckling member 55 isencased in a fabric cover 84 a. Thus, each cushion pad 54 has its ownfabric cover 84 b which prevents the coil spring 36 of the innerpocketed coil spring 82 from contacting and damaging the cushion pad orpads over time, in addition to the inner pocket 35 of fabric of theinner pocketed coil spring 82.

However, each string 26 e lacks divides 64 or “split top” feature. Anyof the embodiments of strings or pocketed spring assemblies shown ordescribed herein may lack the divides or “split top” feature regardlessof the whether one-sided or double-sided.

FIG. 9 illustrates a side view of a pocketed liquid pod which may besubstituted for the liquid pod 55 shown and described herein in any ofthe embodiments shown or described herein. Although many of the liquidpods 55 shown in the drawings are illustrated being un-pocketed, any ofthem may be individually pocketed.

FIGS. 10 and 11 illustrate another embodiment of string 226 which may beused in any single-sided pocketed spring assembly shown or describedherein. FIG. 10 is a view like FIG. 2 illustrating the leftmost outerpocket 34 shown in dashed lines and the inner pocket 35 shown in solidlines. In FIG. 10 , the other outer pockets 34 of string 226 are shownin solid lines and the inner pockets 35 shown in dashed lines. For easeof understanding, like numbers are used for like components whencomparing the one-sided string 26 of FIGS. 2 and 3 to the one-sidedstring 226 of FIGS. 10 and 11 . Each outer pocket 34 of one-sided string226 of FIGS. 10 and 11 has a liquid pod 55 therein but lacks acushioning pad 54 therein when compared to the outer pockets 34 ofstring 26 of FIGS. 2 and 3 . Although coil spring 36 of inner pocketedcoil spring 82 is shown being inside the inner pocket 35, any of thecoil springs shown or described herein may be substituted for coilspring 36 inside the inner pocket 35 of inner pocketed coil spring 82.Although FIGS. 10 and 11 illustrate liquid pods 55 lacking covers, theliquid pods in this embodiment, and any other embodiment, may havecovers as shown in FIG. 6A. Similarly, in this embodiment, and any otherembodiment, liquid pods 55′, as shown in FIG. 2C, may be substituted forliquid pods 55.

As best shown in FIG. 11 , each transverse seam 52 of one-sided string226 has an upper ear 53 at its upper end due to the transverse seam 52extending the full height of the one-sided string 226, from uppersurface to lower surface. Although not shown, one-sided string 226 mayalternatively have transverse seams 152 with an upper divide 64, asshown in the alternative embodiment of string 126 shown in FIGS. 3A and3B.

FIG. 12 illustrates a double-sided string 226 b for use in adouble-sided pocketed spring assembly, such as pocketed spring assembly12 b shown in FIG. 1B for example. The double-sided string 226 b isidentical to double-sided string 26 b shown in FIG. 7 , but withoutcushion pads 54 inside each outer pocket 34 b. Although FIG. 12illustrates liquid pods 55 lacking covers, the liquid pods in thisembodiment, and any other embodiment, may have covers as shown in FIG.6A. Similarly, in this embodiment, and any other embodiment, liquid pods55′, as shown in FIG. 2C, may be substituted for liquid pods 55.

Two liquid pods 55 and an inner pocketed spring 82 b located between theliquid pods 55 are located inside each outer pocket 34 b. One of theliquid pods 55 is located above the inner pocketed coil spring 82 b. Theother liquid pod 55 is located below the other cushion pad 54 and theinner pocketed coil spring 82 b. Although coil spring 36 b of innerpocketed coil spring 82 b is shown being inside the inner pocket 35, anyof the coil springs shown or described herein may be substituted forcoil spring 36 b inside the inner pocket 35 of inner pocketed coilspring 82 b. Although FIG. 12 illustrates liquid pods 55 lacking covers,encased liquid pods or liquid pods of different shapes, or anycombination thereof, may be used in the double-sided string 26 b or anystring shown or described herein.

Like the double-sided string 26 b shown in FIG. 7 , the double-sidedstring 226 b of FIG. 12 has transverse seams 152. The upper end of eachtransverse seam 152 of the string 226 b has a divide 64 extendingdownwardly from an upper surface 60 of the string 226 b. Similarly, thelower end of each transverse seam 152 of the string 226 b has a divide64 extending upwardly from a lower surface 62 of the string 226 b.Although not shown, each of the transverse seams of double-sided string226 b may have upper and lower ears 53, 83 without divides like in thedouble-sided string 26 of FIG. 3C.

FIG. 13 is a schematic illustration of a cross-section of a single-sidedstring 90 for use in a single-sided pocketed spring assembly. Thesingle-sided string 90 comprises an outer pocket 92 having a height H1.A main member 94 having a height H3 is located inside the outer pocket92 at the bottom thereof. A supplemental member 96 having a height H2 islocated above the main member 94 inside the outer pocket 92. The sum ofthe heights H3, H2 of the main and supplemental members 94, 96,respectively, is approximately the same as the height H1 of thesingle-sided string 90. The drawings are not intended to limit theheights of the main and supplemental members 94, 96 to thoseillustrated. The main member 94 may be a pocketed spring, a non-pocketedspring or a pocketed or non-pocketed foam member. The supplementalmember 96 may be a pocketed or non-pocketed liquid pod. Although FIG. 13illustrates the main and supplemental members 94, 96, respectively,being cylindrical, either one of them may be any desired shape.

FIG. 14 is a schematic illustration of a cross-section of a single-sidedstring 98 for use in a single-sided pocketed spring assembly. Thesingle-sided string 98 comprises an outer pocket 100 having a height H4.A main member 102 having a height H5 is located inside the outer pocket100 at the bottom thereof. A first supplemental member 104 having aheight H6 is located above the main member 102 inside the outer pocket100. A second supplemental member 106 having a height H7 is locatedabove the first supplemental member 104 inside the outer pocket 100. Thesum of the heights H5, H6 and H7 of the main and supplemental members102, 104, 106, respectively, is approximately the same as the height H4of the single-sided string 98. The drawings are not intended to limitthe heights of the main and supplemental members 102, 104, 106 to thoseillustrated. The main member 102 may be a pocketed spring, anon-pocketed spring or a pocketed or non-pocketed foam member. The firstsupplemental member 104 may be a pocketed spring, a non-pocketed springor a pocketed or non-pocketed foam member. The second supplementalmember 106 may be a pocketed or non-pocketed liquid pod. Although FIG.14 illustrates the main and supplemental members 102, 104, 106,respectively, being cylindrical, either one of them may be any desiredshape.

FIG. 14A is a schematic illustration of a cross-section of asingle-sided string 98′ for use in a single-sided pocketed springassembly. The single-sided string 98′ is identical to single-sidedstring 98 of FIG. 14 except that the placement of the first supplementalmember 104 is reversed relative to the placement of the secondsupplemental member 106.

FIG. 15 is a schematic illustration of a cross-section of a single-sidedstring 108 for use in a single-sided pocketed spring assembly. Thesingle-sided string 108 comprises an outer pocket 110 having a heightH8. A main member 112 having a height H9 is located inside the outerpocket 110 at the bottom thereof. A first supplemental member 114 havinga height H10 is located above the main member 112 inside the outerpocket 110. A second or middle supplemental member 116 having a heightH11 is located above the first supplemental member 114 inside the outerpocket 110. A third supplemental member 118 having a height H12 islocated above the second or middle supplemental member 116 inside theouter pocket 110. The sum of the heights H9, H10, H11 and H12 of themain and supplemental members 112, 114, 116, 118 respectively, isapproximately the same as the height H8 of the single-sided string 108.The drawings are not intended to limit the heights of the main andsupplemental members 112, 114, 116, 118 to those illustrated. The mainmember 112 may be a pocketed spring, a non-pocketed spring or a pocketedor non-pocketed foam member. The first supplemental member 114 may be apocketed spring, a non-pocketed spring, a pocketed or non-pocketed foammember. The second supplemental member 116 may be a pocketed spring, anon-pocketed spring, a pocketed or non-pocketed foam member. The thirdsupplemental member 118 may be a pocketed or non-pocketed liquid pod.Although FIG. 15 illustrates the main and supplemental members 112, 114,116, 118 respectively, being cylindrical, any one of them may be anydesired shape.

FIG. 15A is a schematic illustration of a cross-section of asingle-sided string 108′ for use in a single-sided pocketed springassembly. The single-sided string 108′ is identical to single-sidedstring 108 except that the placement of the second supplemental member116 is reversed relative to the placement of the third supplementalmember 118.

FIG. 16 is a schematic illustration of a double-sided string 290 for usein a double-sided pocketed spring assembly. The double-sided string 290comprises a main member 294 and two supplemental members 296 encased byan outer pocket 292. As shown in FIG. 16 , the double-sided string 290in a relaxed condition has a height HH1. The main member 294 has aheight HH3 and is located inside the outer pocket 292 between the twosupplemental members 296. Each supplemental member 296 inside the outerpocket 292 has a height HH2. The sum of the heights HH3, HH2 of the mainand supplemental members 294, 296 is approximately the same as theheight HH1 of the double-sided string 290 when the double-sided string290 is in a relaxed condition as shown in FIG. 16 . The drawings are notintended to limit the heights of the main and supplemental members 294,296 to those illustrated. The main member 294 may be a pocketed spring,a non-pocketed spring or a pocketed or non-pocketed foam member. Eachsupplemental member 296 may be a pocketed or non-pocketed liquid pod.Although FIG. 16 illustrates the main and supplemental members 294, 296being generally cylindrical, any of them may be any desired shape.

FIG. 17 is a schematic illustration of a cross-section of a double-sidedstring 298 for use in a double-sided pocketed spring assembly. Thedouble-sided string 298 comprises a main member 202, two innersupplemental members 204 and two outer supplemental members 206. Themain member 202, two inner supplemental members 204 and two outersupplemental members 206 are encased by an outer pocket 200. As shown inFIG. 17 , the double-sided string 298 in a relaxed condition has aheight HH4. The main member 202 has a height HH5 and is located betweenthe two inner supplemental members 204 inside the outer pocket 200. Eachinner supplemental member 204 has a height HH6. An upper or first innersupplemental member 204 is located above the main member 202 inside theouter pocket 200. A lower or second inner supplemental member 204 islocated below the main member 202 inside the outer pocket 200. An upperouter supplemental member 206 having a height HH7 is located above theupper inner supplemental member 204 inside the outer pocket 200. Asecond or lower outer supplemental member 206 having a height HH7 islocated below the lower inner supplemental member 204 inside the outerpocket 200. The sum of the heights HH5, HH6 and HH7 of the main andsupplemental members 202, 204, 206, respectively, is approximately thesame as the height HH4 of the double-sided string 298 when thedouble-sided string 298 is in a relaxed condition. The drawings are notintended to limit the heights of the main and supplemental members 202,204, 206 to those illustrated. The main member 202 may be a pocketedspring, a non-pocketed spring or a pocketed or non-pocketed foam member.Each inner supplemental member 204 may be a pocketed spring, anon-pocketed spring, a pocketed or non-pocketed foam member. Each outersupplemental member 206 may be pocketed or non-pocketed liquid pod.Although FIG. 17 illustrates the main and supplemental members 202, 204,206, respectively, being certain shapes, any one of them may be anydesired shape.

FIG. 17A is a schematic illustration of a cross-section of adouble-sided string 298′ for use in a single-sided pocketed springassembly. The double-sided string 298′ is identical to double-sidedstring 298 of FIG. 17 except that the placement of the supplementalmember 204 is reversed relative to the placement of the supplementalmember 206.

FIG. 18 is a schematic illustration of a cross-section of a double-sidedstring 208 for use in a double-sided pocketed spring assembly. Thedouble-sided string 208 comprises an outer pocket 210, two innersupplemental members 214, two middle supplemental members 216 and twoouter supplemental members 218. The main member 212, two innersupplemental members 214, two middle supplemental members 216 and twoouter supplemental members 218 are encased by an outer pocket 110. Asshown in FIG. 18 , the double-sided string 208 in a relaxed conditionhas a height HH8. The main member 212 has a height HH9 and is locatedbetween the two inner supplemental members 214 inside the outer pocket210. Each inner supplemental member 214 has a height HH10. An upper orfirst inner supplemental member 214 is located above the main member 212inside the outer pocket 208. A lower or second inner supplemental member214 is located below the main member 212 inside the outer pocket 210. Anupper middle supplemental member 216 having a height HH11 is locatedabove the upper inner supplemental member 214 inside the outer pocket210. A second or lower middle supplemental member 216 having a heightHH11 is located below the lower inner supplemental member 214 inside theouter pocket 210. An upper outer supplemental member 218 having a heightHH12 is located above the upper middle supplemental member 216 insidethe outer pocket 210. A second or lower outer supplemental member 218having a height HH12 is located below the middle supplemental member 216inside the outer pocket 210. The sum of the heights HH9, HH10, HH11 andHH12 of the main and supplemental members 212, 214, 216, 218,respectively, is approximately the same as the height HH8 of thedouble-sided string 208 when the double-sided string 208 is in a relaxedcondition. The drawings are not intended to limit the heights of themain and supplemental members 212, 214, 216, 218 to those illustrated.The main member 212 may be a pocketed spring, a non-pocketed spring, apocketed or non-pocketed foam member. Each inner supplemental member 214may be a pocketed spring, a non-pocketed spring, a pocketed ornon-pocketed foam member. Each middle supplemental member 216 may be apocketed spring, a non-pocketed spring, a pocketed or non-pocketed foammember. Each outer supplemental member 218 may be a pocketed ornon-pocketed liquid pod. Although FIG. 18 illustrates the main andsupplemental members 212, 214, 216, 218, respectively, being certainshapes, any one of them may be any desired shape.

FIG. 18A is a schematic illustration of a cross-section of adouble-sided string 208′ for use in a double-sided pocketed springassembly. The double-sided string 208′ is identical to single-sidedstring 208 of FIG. 18 except that the placement of the secondsupplemental member 216 is reversed relative to the placement of thethird supplemental member 218.

As shown in FIGS. 13-18 , whether a string is single-sided ordouble-sided, without its fabric outer cover, any number of combinationsof springs, foam and buckling members are possible. Any one or more ofthe springs, foam and liquid pods may be encased in its own fabriccover. Any one or more of the springs, foam and liquid pods may be anydesired shape.

Referring now to FIG. 19 , longitudinally extending strings of springsare shown in one preferable arrangement for a pocketed spring assembly12 d for a bedding or seating product, such as a mattress. As can beseen, the longitudinally extending strings of springs are arranged in aplurality of zones. By way of example, two zones 72, 44 are illustrated,with the zones corresponding roughly to a “warm” side and a “cool” side.By way of further example, the longitudinally extending strings ofsprings of the “warm” zone 72 are each strings of springs having noliquid pods as shown and described herein. The longitudinally extendingstrings of springs of the “cool” zone 74 are each strings of springshaving liquid pods in the outer pockets thereof. Of course, otherarrangements are within the scope of the invention. For example, themattress shown in FIG. 15A may comprise transversely extending stringsof springs rather than longitudinally extending strings of springs. Insuch an arrangement, each transversely extending string of springs wouldhave to be half firm and half soft. Therefore, each string of springswould have only half the string having the liquid pods, the other halflacking liquid pods. Of course, other arrangements are within the scopeof the invention. For example, the pocketed spring assembly shown inFIG. 19 may have a certain type of liquid pod in the strings of one ofthe sections and different liquid pods in the other section.

Referring now to FIG. 20 , the transversely extending strings of springsare shown in one preferable arrangement for a pocketed spring assembly12 e for a bedding or seating product, such as a mattress. As can beseen, the transversely extending strings of springs are arranged in aplurality of zones on the mattress. By way of example, three zones areillustrated, with the zones corresponding roughly to the location of asleeper's head and shoulders, mid-section, knees and feet. By way offurther example, the two end “warm” zones 86 each comprise strings ofsprings having no liquid pods as shown and described herein. Thetransversely extending strings of springs of the middle or “warm” zone88 are each strings of springs having liquid pods. Of course, otherarrangements are within the scope of the invention. For example, thepocketed spring assembly shown in FIG. 20 may have a certain type ofliquid pod in the strings of the middle section and different liquidpods in the two end sections.

The various embodiments of the invention shown and described are merelyfor illustrative purposes only, as the drawings and the description arenot intended to restrict or limit in any way the scope of the claims.Those skilled in the art will appreciate various changes, modifications,and improvements which can be made to the invention without departingfrom the spirit or scope thereof. The invention in its broader aspectsis therefore not limited to the specific details and representativeapparatus and methods shown and described. Departures may therefore bemade from such details without departing from the spirit or scope of thegeneral inventive concept. For example, more than two cushion pads ormore than one inner pocketed spring may be inside an outer pocket. Theinvention resides in each individual feature described herein, alone,and in all combinations of any and all of those features. Accordingly,the scope of the invention shall be limited only by the following claimsand their equivalents.

What is claimed is:
 1. A bedding or seating product comprising: apocketed spring assembly comprising a plurality of parallel strings ofsprings, each of said strings being joined to at least one adjacentstring, each of said strings comprising a piece of fabric surrounding aplurality of inner pocketed springs and a plurality of liquid pods,first and second opposed plies of fabric being on opposite sides of theinner pocketed springs and liquid pods, a plurality of outer pocketsformed along said string by a longitudinal seam and transverse seamsjoining said first and second plies, at least one inner pocketed springand at least one liquid pod being in each of said outer pockets;cushioning materials; and a covering encasing said pocketed springassembly and cushioning materials.
 2. A bedding or seating productcomprising: a pocketed spring assembly comprising a plurality ofparallel strings of springs, each of said strings being joined to atleast one adjacent string, each of said strings comprising a piece offabric surrounding a plurality of inner pocketed springs and a pluralityof liquid pods, first and second opposed plies of fabric being onopposite sides of the inner pocketed springs and liquid pods, aplurality of outer pockets formed along said string by a longitudinalseam and transverse seams joining said first and second plies, at leastone inner pocketed spring and at least one liquid pod being in each ofsaid outer pockets.
 3. The product of claim 2, wherein each of theliquid pods is individually pocketed.
 4. The product of claim 2, whereinan upper end of each of said transverse seams is below an upper surfaceof the string to partially separate adjacent outer pockets.
 5. Theproduct of claim 2, further comprising at least one cushion pad insideeach of the outer pockets.
 6. The product of claim 5, wherein one of thecushion pads and one of the liquid pods are pocketed together inside oneof the outer pockets.
 7. The product of claim 2, wherein at least onecushion pad and at least one liquid pod are above one of the innerpocketed springs inside each of the outer pockets.
 8. A pocketed springassembly for a bedding or seating product, said pocketed spring assemblycomprising: a plurality of parallel strings of springs, each of thestrings being joined to at least one adjacent string, each of thestrings comprising a plurality of interconnected outer pockets made fromone piece of fabric, each of the outer pockets containing at least oneinner pocketed spring, at least one cushion pad and at least one liquidpod, the piece of fabric being joined to itself along a longitudinalseam and having first and second opposed plies of fabric on oppositesides of the springs, the first and second plies being joined bytransverse seams between adjacent inner pocketed springs.
 9. Thepocketed spring assembly of claim 8, wherein two cushion pads and twoliquid pods are in each of the outer pockets.
 10. The pocketed springassembly of claim 9, wherein said at least one inner pocketed spring isbetween the cushion pads and between the liquid pods in each of theouter pockets.
 11. The pocketed spring assembly of claim 8, wherein eachof said transverse seams forming adjacent outer pockets of said stringhas one end located below an upper surface of said string to partiallyseparate adjacent outer pockets.
 12. The pocketed spring assembly ofclaim 11, wherein the inner pocketed springs are below the upper end ofadjacent transverse seams.
 13. The pocketed spring assembly of claim 8,wherein each of said cushion pads is made at least partially of foam.14. The pocketed spring assembly of claim 8, wherein each of the cushionpads is individually pocketed.
 15. A pocketed spring assembly for abedding or seating product, said pocketed spring assembly comprising: aplurality of parallel strings of springs, each of the strings beingjoined to an adjacent string, each of the strings comprising a pluralityof interconnected outer pockets made from one piece of fabric, each ofthe outer pockets containing one inner pocketed spring, at least oneliquid pod, the piece of fabric being joined to itself along alongitudinal seam and having first and second opposed plies of fabric onopposite sides of the inner pocketed springs, the fabric of said firstand second plies being joined by transverse seams, wherein each of saidtransverse seams forming adjacent pockets of said string has an upperend located below an upper surface of said string to partially separatesaid adjacent outer pockets and enable some of the liquid pods tocompress without substantially compressing other liquid pods withinother outer pockets.
 16. The pocketed spring assembly of claim 15,wherein each of said liquid pods comprises an outer pouch surrounding aplurality of beads.
 17. The pocketed spring assembly of claim 15,wherein each of said liquid pods comprises an outer pouch surrounding avolume of liquid.
 18. The pocketed spring assembly of claim 17, whereinsaid outer pouch is made of plastic.
 19. The pocketed spring assembly ofclaim 15, wherein further comprising a cushion pads inside each of theouter pockets.
 20. The pocketed spring assembly of claim 19, whereineach of the cushion pads is made at least partially of foam.